Winding flexible material



Oct. 30, 1962 Filed Aug. 14, 1957 w. P. TAYLOR, JR 3,061,238

WINDING FLEXIBLE MATERIAL ll Sheets-Sheet 1 1N VENTOR ATTORNEYS Oct. 30,1962 w. P. TAYLOR, JR

WINDING FLEXIBLE MATERIAL 11 Sheets-Sheet 2 Filed Aug. 14, 1957 %m./%g/, BYzx W ATTORNEYS? Oct. 30, 1962 w. P. TAYLOR, JR 3,061,238

WINDING FLEXIBLE MATERIAL Filed Aug. 14, 1957 ll Sheets-Sheet 4 .9 L gK3 9 Oct. 30, 1962 w. P. TAYLOR, JR 3,061,238

WINDING FLEXIBLE MATERIAL Filed Aug. 14, 1957 11 Sheets-Sheet 5 INVENTOROct. 30, 1962 w. 'P. TAYLOR, JR 3,061,238

WINDING FLEXIBLE MATERIAL Filed Aug. 14, 1957 ll Sheets-Sheet 6 A'ITOEYS Oct. 30, 1962 w. P. TAYLOR, JR 3,061,238

WINDING FLEXIBLE MATERIAL Filed Aug. 14, 1957 11 Sheets-Sheet 9 Oct. 30,1962 w. P. TAYLOR, JR

WINDING FLEXIBLE MATERIAL 11 Sheets-Sheet 10 Filed Aug. 14, 1957INVENTOR Oct. 30, 1962 w. P. TAYLOR,IJR 3,061,233

WINDING FLEXIBLE MATERIAL Filed Aug. 14, 1957 ll Sheets-Sheet 11 \LJSZgUnited States Patent 3,061,238 WINDING FLEXIBLE MATERIAL Walter P.Taylor, Jr., New York, N.Y., assignor of onehalf to James W. NewmanFiled Aug. 14, 1957, Ser. No. 678,106 5 Claims. (Cl. 242-163) Theinvention relates to machines and methods of winding long lengths offlexible material such as wire, yarn, thread, rope, ribbon, tape, cable,and the like, and to methods of modifying and packaging suchwindings,'to the packages so produced, and to the spools on which thepackages are wound. More especially, it relates to the winding andpackaging of any bendable filamentous or ribbon-like substance,including all cross sectional shapes of wire or other substances andespecially those with slippery surfaces.

The primary object of the invention is to produce an improved package orcoil of flexible material in which the substance crosses over itself atrelatively widely spaced intervals to avoid destructive bends from thescissors action of close crossovers, is reversed at the ends of the packHeretofore, completely self-supporting winds in this art have beendependent on the bonding quality or frictional adherence of the woundsubstance, plus close lay of adjacent coils (closed advance) and hightension on the winding line, two conditions which combine to increasethe bondingefiect by crimping-in the line during winding and thereafterholding it in place under pressure.

Because many'substances lack sufliicient bonding quality (are tooslippery or too hard-and-round) to be held se-- curely, either duringthe winding or after, and because most are damaged or deformed by theshearing action of adjacent strands in close lay winds, by lengthwisestretch from high tension, by bends and rubbing from being pulled athigh tension over the angular structure of the ends of this form ofwinding, by bends in the line from angular deflection in the path of thewind at the ends, or by the pressure of strand on strand that is builtup in the wall of a long length winding, these completelyself-supporting winds have been utilized for only a few substances suchas cord and rope and in relatively short lengths. In addition,development has been restricted almost entirely to the ball of cord orone-half wind type which lacks adaptability to changes in shape orwinding angle, is limited in relative size (length that can be wound),and has.

little stability for anything but cord. In addition, this form allows noequalization of twist, being wound without the radial hole described inmy Patent No. 2,634,922.

It is an object of the present invention to eliminate all of thesediificulties. It provides a self-supporting winding and the mandrel andend forms on which it is to be wound, fitted to the specific conditionsof any machine of' In addition, since it can be the quick traverse type.worked out for any size and for any angle of wind, it produces woundpackages with the best combination of self-- 2 f: out any bendablesubstance, particularly flat or tapelike substances which heretoforehave proved troublesome and which frequently require complicatedmachinery for successful winding on reels or spools of current design.

Another object of the invention is to produce variations. of the samewinding which contain a hole radially through the wall, yet which remaincompletely self-supporting so that the line can be withdrawn from theinside through thef radial hole.

One more object of the invention is to provide a method of designingends for any shape of the central part of a mandrel, across which it isknown that a winding. line will traverse, so that the combinationwillfit prede-' termined machine adjustments of reasonable size (or so thatcorrect machine adjustments can be determined for 'a" preferredcombination), a complete mandrel can be con structed correctly and thecombination of center and ends will prove windable and will result in aself-supporting package.

Another object of the invention is to provide a method of designing bywhich self-supporting end formations, such that the wound substance isnot subjected to angular bends in turning back, can be provided for anyshape of regular (as opposed to random) winding.

Still a further object of the invention is to produce variations of thesame windings which are contracted or collapsed circumferentially insome part or over all their lengths or are partially or completelyflattened circum- An additional object of the invention is to producevariations of the type containing a radial hole which are collapsedradially from each side of the radial hole so as to. leave a series ofnested figure eight coils.

Still another object of the invention is to provide packaging of suchcoils with regard to their characteris-' tics gained from the aboveprocessing so as .to protect them during handling and to facilitatewithdrawalof the substance with the least resistance and with theminimum possibility of harming the substance during the withdrawal.

This application is a continuation-in-part of my prior' applicationSerial No. 344,875, filed March 26, 1953, now Patent No. 2,828,092 whichin turnwas a continu ation-in-part of my application Serial .No.107,165, filed July 28, 1949, now Patent No. 2,634,922.

In my prior applications, referred to above, I have described. certain.package shapes .in connection with'a coil formed of figure eights andhaving a radial holeinto the central axial hole through which the innerend of the material can be drawn out. I have now found that theprinciple of. these shapes, if the proper relative dimensioning of theparts is observed, is applicable to windings which do not have radialopenings, and that improved packages, both with and without suchopenings, can be produced; also, that the principle on which successfulwinding of such shapes depends is a systeni'- of forming wound endswhich can be applied success fully to any type of windings exceptthosewhich might: be considered truly random. 1 7

Further objects and advantages of the invention willappear morefullyfrom the following description, especially when taken inconjunction with the accompany ing drawings which form apart thereof.

In the drawings,

FIGURE 1 illustrates diagrammatically a machine embodying the invention;

FIGURE 2 shows the basic manner of determining the shape of a spindleaccording to the invention;

FIGURES 3 and 4 are explanatory diagrams in connection with FIGURE 2;

FIGURE 5 shows the manner of forming a spindle having a radius less thanthe base radius;

FIGURE 6 shows the way of forming a spindle for a Universal one-windhaving a positive or negative advance;

FIGURES 7 and 8 show the forming of a spindle for a twowind, with apositive advance;

FIGURE 9 is an englargement of a part of FIGURE FIGURES 10 and 11 showthe forming of a spindle for a three-wind with a negative advance;

FIGURE 12 is an enlargement of a part of FIGURE 10;

FIGURES 13 and 14 are cross-sections through packages embodying theinvention;

FIGURE 15A shows a package produced in accordance with the invention;

FIGURES 15B and 15C show the package of FIG- URE 15A collapsed in twodifferent ways;

FIGURE 16A shows another package embodying the invention;

FIGURES 16B, 16C and 16D show the package of FIGURE 16A collapsed invarious ways;

FIGURE 17A shows another type of package embodying the invention;

FIGURE 17B shows the package of FIGURE 17A collapsed.

FIGURE 18 shows a further form of package embodying the invention.

FIGURE 19A shows a further package embodying the invention;

FIGURE 19B shows the package of FIGURE 19A in collapsed condition.

FIGURE 20A shows a package which is to be circumferentially collapsed;

FIGURES 20B and 20C show, in front view and side elevation, the packageproduced by the circumferential collapse of the package of FIGURE 20A;

FIGURE 21A shows in side elevation a holder for the package of FIGURE20B;

FIGURE 21B is an end view of this holder;

FIGURE 21C is a top plan view thereof;

FIGURE 22 shows another form of holder;

FIGURES 23A and 23B are a front view and a side elevation respectivelyof a circumferentially collapsed package of a two-wind;

FIGURE 24 shows another type of holder for packages embodying theinvention;

FIGURE 25 is an explanatory diagram for the spooling of flat material;

FIGURE 26 shows the spool for winding flat material in side elevation;

FIGURE 27 shows the construction of a spindle embodying the invention;

FIGURE 28 is a cross-section on the line 2828 of FIGURE 27;

FIGURE 29 shows a spindle in which the central portion is notcylindrical; and

FIGURE 30 shows still a further form of mandrel.

FIGURE 1 shows diagrammatically a basic form of machine for windingflexible material embodying the invention. This diagram is based on aZero advance and a one wind, that is, a wind in which the spindle makestwo complete revolutions for each complete reciprocation of the guide.

Such a machine, according to the invention, includes a spindle havingcylindrical central portion 12, portions 14 of outwardly decreasingdiameter at each end of the central portion, and outwardly flaring endforms 16 beyond portions 14, and a guide 18 for the flexible material,which moves parallel to the spindle axis.

The basic form of spindle shown in FIGURE 2 is for a one wind with zeroadvance. Later figures show the adaptation of this form to advancing(positive or negative or plus-minus) winds and to Winds of a differentnumber or order than one, as well as the adaptation of the endformations of the type shown in this figure to a wind of any shapedcentral portion.

In the basic machine, the cylindrical portion 12 of the spindle ormandrel has a radius R. The guide 18 moves at a distance 2R from theaxis of the spindle (see FIG- URE 4); in FIGURE 2, the distance is lesssince, as will be explained below, this is a projection of the guidestravel on a plane at an angle of 30 through the spindle axis.

With reference to FIGURE 2, the guide is assumed to travel in a path G,the axis of the spindle being shown at A, and the center line at Cperpendicular to and passing through the center 20 of line G. Thecentral cylindrical portion of the spindle is represented by lines R Ron either side of axis A, parallel thereto and at a distance Rtherefrom.

To lay out the cross-section of the spindle or mandrel, I lay off on thecenter line C from axis A a distance equal to 1rR/2 to point 21, thisrepresenting one-fourth the circumference of the central portion of thespindle. Line G (in this drawing) is at a distance R /3 from the spindleaxis on the other side from point 21. Angle 22-21-20 is called thewinding angle (angle a, in this case 30), representing the angle atwhich the material is wound on the central portion of the mandrel in thefirst layer. Line 23 from 21 to 22 indicates the winding line laid outflat.

I now locate point 24 on center line C at a distance R from the spindleaxis and draw a line 25 from this point to point 26 (the common orover-the-axis point) where line 23 intersects axis A. Angle 20--24-26 isdesignated angle B, the cylindrical helix generating line angle. Throughpoint 26 I draw another line 27 on the other side of the axis from line25 and forming the same angle with line 23 to point 28. I also draw aline through point 26 perpendicular to axis A to its intersection atpoint 29 with line R Angle 28-26'29 is designated angle '7 (in this case17 47 /2). Through point 29 I draw a line sloping inwardly toward theaxis A and intersecting it at 30, the the angle 26 2930 being equal tohalf the angle 7 (8 53 /4). I then draw a line 31 (junction line)through 30 perpendicular to axis A, this line indicating the plane ofone end of the cylindrical portion 12 of the spindle and intersectingline R at 32 and R at 32'.

With 30 as a center and R as a radius, I describe an are i 51 from point32 to point 33 on line 27. This curve represents the outline of theportion 14 of the spindle of outwardly decreasing diameter.

Through point 33, I draw a line 34 parallel to line 25 and extending outas far as line G. This line represents the outwardly flaring end form16.

The remainder of the spindle is laid out symmetrically, and thisrepresents the cross-section of the spindle.

The shape of the basic spindle is determined entirely by the chosenwinding angle, the radius of the spindle and the length of the guidestroke. If any two of these are known, all other values and angles canbe calculated.

Assuming a spindle of Radius R and a guide having a path of travel 2G,

A a=tan- The length of the cylindrical portion 12 (from center line topoint 30) is:

REtan {3 tan (ct-5)] The axial projection of the arcuate portion 14 is:

R sin +6) where 6=sin"' (cos 7 tan The winding angle as set forth inFIGURE 2 is for the layer of radius R. With the same guide distance,this angle will decrease as the layers build up on the spindle, while ifa spindle of less diameter is used, the winding angle will be greater.

Referring to FIGURES 3 and 4, FIGURE 4 shows spindle axis A with aseries of semicircles r, 1- to r;, (r being the base diameter) and r2(for convenience, circles r and r are shown in solid lines, r and r inbroken lines, and r2 in dot and dash lines, the other correspondinglines in the diagram being correspondingly shown). G represents the lineof travel of the guide. T, T to T and T2 lines from G are drawn tangentto the various arcs at 1, t to t and t2 respectively.

The winding angle (FIG. 3) at any radius r is determined by a trianglewhose base is half the length of the line of travel of the guide, or G,and whose height is the sum of the distance from line G to the point oftangency t plus the length of the arc of radius r from this point oftangency to the line B displaced by 150 around the axis A from line A-G(FIGURE 4).

The total length of the leg of the Winding triangle is laid out on linesP, P P P P2 parallel to the line B and tangent to circles r, r r ,'rr-Z'. The quarter of the circumference from line B back towards G can beshown by intersection of a line D, drawn at angle of 32 29' to line B,this being the angle whose cotangent equals 1r/2. The distance from lineE, perpendicular to line B, to line D represents the arc length.

The sum of the distance from point G to tangent points I, I etc., plusthe arc from this tangent point to line B, -I have found, is almostexactly equal, when r is greater than R, to the distance along line Pfrom line D to an arc F of a circle whose radius is 3R/2, whose centeris on line P and which passes through point G.

For a radius less than R, the sum of the distance from point G to pointt plus the are from this point to line B is substantially equal to thedistance along line P to an arc F of a circle whose radius is 2R, whosecenter is on line P and which passes through point G.

Now, by projecting from FIGURE 4 to FIGURE 3, I mark a point such as Jon center line C of FIGURE 3 opposite the intersection of line P withline D. I also draw a line G parallel to line G and passing throughpoint H where line P intersects arc F line G intersecting at K a lineperpendicular to G through end point 22 thereof. Angle K -J thenrepresents the winding angle for circle r Since the distance 20-22,equal to R(1r+2 tan a p 2 is the base of the triangle, and the. length Pfor any radius r is then thewinding angle 0a,; is

tan-

where R is the radius at which the winding angle a has the value tan- ,8being the angle of the conical interior end portions. The flexiblematerial is wound on the spindle or on the previously wound material insuccessive figure 8s,-

the material crossing over itself on the center line C for zero advanceor on lines near to and parallel to C for advanced (positive ornegative) winds. Each half of the loops which form the figure 8 isdivided into two parts, which I have called cylindrical helix and greatcircle respectively. The portion of the material wound, on as thecross-over point turns from the point of tangency t (FIG. 4) to the lineB is cylindrical helix.

During this part of the rotation, the guide is moving outward from itscentral position to point 22.

When the guide reverses at point 22, reversed great circle begins toform, this continuing while the spindle turns from line B opposite lineB to point t During the next phase, forward great circle is formed;

while the spindle turns through the same number of degrees as forreversed great circle, and then cylindrical helix for the balance of thecomplete revolution back to the cross-over point. The same cycle is thenrepeated onthe other half of the spindle.

In FIGURE 2, I have shown at 35 the cross-over point, at 35-36 the firstphase of cylindrical helix, at 36-37 the reverse great circle, at 37-33the forward great circle, and at 38-35 the second phase of cylin dricalhelix. 1 have also shown the appearance of onefourth of the figure 8displaced by 24 being the cross-over point, 24-40 the cylindrical helixand 40-41 the reversed great circle.

A package wound on such a machine will have an internal surfacecorresponding to the outside of the mandrel, that is, the internalsurface will have a central part of cylindrical shape, and two portionsof gradually decreasing diameter. The outer surface and all layerscornposing the winding will have this same shape, the ends 1 of thelayers forming outwardly flared or conical ends.

FIGURE 5 shows the construction of a spindle where it is desired to usea minimum diameter less than the base diameter R (that is, less thanhalf the distance between.

the path of travel of the guide and the axis of rotation of thespindle). In this figure, A is the axis and G is the path of the guideat a distance (as shown in the figure).

RV? from the spindle axis. Assuming a diameter R,

less than R, I first locate point 21 on the center line C at a distance1rR/2- from the axis, and draw line 21-22 to one end of guide travel G,intersecting axis A at 26. Now from point 24 on the center line atdistance R from the axis I draw line 25 from point 24 through 26. Next,"

line 27 is drawn, with angle 22-26-28 equal to angle 21-26-24. Point 33and line 34 (the end cone line), parallel to line 24-26, are constructedas in FIGURE 2.

Lines R and R -are drawn, representing the cylindrical part of thespindle, parallel to and at a distance R from axis A. Then a line isdrawn from point 22 to point 42 on the center line at a distance n'R/ 2from; the axis A, this line crossing the axis at point 43. Nowvand theend cone line 34 constitute the remainder of the shape of this quarterof the cross-section of the spindle.

When a package is wound on such a spindle, the layer of radius R willhave substantially the configuration of the outside of the spindle ofFIGURE 2, and will satisfy the equations given above.

Of course, in actual practise, it is usual not to have all thecrossovers at the same angular position of the spindle but to cause suchcrossovers to progress angularly around the spindle in the so-calleduniversal wind. This is accomplished by having the rotation of thespindle slightly out of phase with the movement of the guide, so thatfor example fora one wind for each thirty complete reeiprocations of theguide the spindle makes sixty-one revolutions (positive advance or pluswind) or fiftynine revolutions (negative advance or minus Wind).

FIGURE 6 shows the manner of constructing a spindle for either a plus ora minus wind. Again, A is the axis of rotation of the spindle and G thepath of travel of the guide at a distance (in the drawing) of R /3 fromthe axis. The guide actually is positioned at a distance 2R from theaxis, but FIG. 6 is a view taken at an angle of 30 to the plane of theguide movement. This figure is based on a winding angle of 45, and anadvance of 6. Point 21 and lines R and R are located as in FIGURE 2.

For a plus wind, point 21 is located on the center line at a distance1rRa 720 2 (where tip is crossing the axis at 30p. Also a line 27 isdrawn through point 26p making an angle (Bpap) with line 21p-22. Nowwith point 30p as a center and radius R 'an arc is drawn from the pointof tangency 32p of line R to the intersection 28p with line 27p. Now aline 34p is drawn through point 28p forming an angle pp with center lineC. This is the end form line. Line R are 32p-28p and line 34p thenoutline one-fourth of the cross-section of the spindle.

For a minus wind, point Zln is located closer to the axis than point 21by a distance rrRa 720 The winding angle cm is 2021n22, and angle fin is1r tan an tan- 2 150+g-cos- Ju -rat,

where R is the radius at which the winding angle up has the value tan-16p 3p being the angle of the conical interior end portions. For anegative angle, the winding angle a at radius where R is the radius atwhich the winding angle has the value 2 tan 6n -1 tan r The length ofeach half of the cylindrical portions of the spindle for a positiveadvance is [(360+a) tan tip-360 tan (u 9] R 360 The axial projection ofthe arcuate portion 14p is R sin (WP-HP) where 5p=sin (cos p tan 2 and pis Zap-61). The angle of the end form is ,Bp.

For a negative advance, the length of the cylindrical portion is where612 is sin (cos 'yn tan 'yn/Z) and n is 2an-fin. The end form angle is5n.

The spindles previously described have been those fo use with one winds.For winds of other orders, the spindle is laid out as shown in FIGURES 7to 12, which show the spindles for a two wind (FIGURES 7 to 9) and athree wind (FIGURES 10 to 12) respectively.

With reference to FIGURES 7 to 9, assuming a basic winding angle 0/2 of15, and a guide moving in a path G at a distance 2R(R /3 in FIGURE 8)from the axis A, the leg PL of the winding triangle is AP (arcedportion) plus TP (tangent portion). The aroed portion AP is equal to theportion around one-fourth of the circumference (as for a one wind) plusan additional onebalf perimeter for each order over one. For a two"wind, then,

and for any other wind of order N,

AP=1rR plus 1rR(N-- 1) TP, of course, is R Therefore,

Assuming a basic winding angle a, the distance 2022 will be or, for atwo wind,

For a positive or negative advance, the leg of the winding triangle isfound by adding to or subtracting from PL an amount depending on thenumber of degrees of advance (a) and the order N. PL then becomes, for apositive advance,

The winding angle ap for a positive advance is while for a negativeadvance the winding angle an is 7! PL or R ($776 since N=l, is measuredofi (FIGURE 7) on C from tan" I a l- An arc with radius R is drawn fromthe point of tangency 32 with line R to the (intersection 28 with line27 A line 34 through point 28 at an angle 6' to the line C gives the endform.

In such a package, the leg of the winding triangle at radius r will be,for a positive advance,

and for a negative advance plus (N 1) The distance 2tt22 is The windingangle a'p at radius r is therefore for a positive advance taxr the axisA to locate point 21 and line 21 -42 is drawn, intersecting the axis at26 A perpendicular from 26 intersects line R at 29 and a line is drawninwardly from 29 at an angle intersecting the axis at 30 A line 27 isalso drawn tanthrough 26 at an angle fi' -a' to line 21 -42 An arc isnow drawn with 30 as a center and R as a radius from the point oftangency 32 with line R to the intersection 28 with line 27 A line 34through point 28 is then drawn at an angle 5' to the center line C. LineR are 32 28 and line 34 define the outline of onefourth of thecross-section of the spindle.

For a negative advance, the same procedure is followed. FIGURES 10 to 12show the forming of a spindle for equals I tanfl 2 tan B gr fl'p beingthe angle of the conical end portions.

For a negative advance, winding angle en at radius r is 4N am where R isthe radius at which the winding angle a'n is tanfl 2 tan 5 n fl'n beingthe angle of the conical end portions.

For any such package, by inspection ,B'p, fl'n, r and a can be found.From these, up, un and R can also be found and it can be determinedwhether the package satisfies the desirable conditions.

where R is the radius at which the winding angle ac'p- The spindle ofsuch a machine, for a positive advance, has a cylindrical portion oflength For a negative advance, the cylindrical portion has a length ofThe projection of the arcuate portion on axis A is R sin ('y'n-H'n)where 6'n is sin (cos 'yn tan 2 The end form angle is Bn.

In other words, the distance across the base layer (layer of radius R)corresponding to distance 33-33 in FIGURE 2 is In each modification, theend form generating line will intersect the axis of the spindle at adistance from the center line C equal to FIGURE 13 shows a packageproduced according to the invention where the ordinary universal windmachine, such as shown in the patent to Wardwell, No. 480,157, is usedbut with the guide moving in a fixed line. This package has a centralaxial core with a cylindrical center part 62, intermediate parts 64 ofoutwardly decreasing cross-section, and outwardly flaring ends 66.

FIGURE 14 shows a package produced on a machine such as that shown inthe Taylor and Whipple Patent No. 2,634,918, in which, by varying therelative speed of the spindle and guide, a radial hole is produced intothe axial core through which the inner end of the material can be drawnout. The central axial core has the same shape, but there is a radialhole 70 through which the inner end of the material can be withdrawn.

Such a package may also be produced with alternating plus and minuswinds, as described in my application for Winding Flexible Material,S.N. 344,874, filed March 26, 1953, now Patent No. 2,767,938.

The general theory of why the design of my mandrel and shape of windingis so advantageous is not easy to define. However, I believe I haveproved that there is a shape (or formation) that incorporates a specificshortest path on its surface, the shape and the path being so contrivedthat a winding machine of the quick traverse type causes a woundsubstance to form continuously over that path in such a way that therelative shape and its relative shortest path are retained throughoutthe growth of any winding; and that this combination results in thegreatest possible stability for the wound substance both during thewinding and in the unsupported package of wound substance that results.

Another part of the theory is that I have invented a wound packageformed of overlaid loops and a shape on which to wind it, each half ofeach loop being composed of a combination of cylindrical helix and greatcircle, the great circle being at an angle complementary to the angle ofthe helix, the whole contrived so that, regardless of the ratio ofdegrees of turn of cylindrical helix to the degrees of turn of reversegreat circle, the half loop will always follow approximately the samerelative path.

Another point is that I have invented a wound package formed of overlaidloops, and a shape on which to wind it, in which no part of any loop issubjected to angular deflection.

Every loop of such a package contains, at its outer end, two greatcircle portions which are complementary to its cylindrical helixportions.

The most stable windings, composed of a number of layers, appear to bethose in which there is the lea-st rapid change of winding angle fromlayer to layer. From this it follows that the innermost and outermoststages are generally somewhat less stable; also, that the central layersof a large diameter design are somewhat more stable than a wider span oflayers of a small diameter design. However, when solving a particularproblem of mechanics of winding or to obtain a specific result in thewound package, there are possible advantages in all stages that shouldbe considered.

If there are limitations in the machine to be used, it is obvious thatmore substance can be built into a winding that starts at a minimumstage and proceeds to a maximum. Also, if control of the wound substanceduring payout is being sought and there is a limit to the width of throwof the guide that prevents winding at a wider angle, the inner stages,at any angle of wind, have relatively more end closure than the outerstages. This closure tends to control the loops during payout.

There is a mechanical and a control advantage in winding the outerstages. The shorter the relative distance from guide to tangent point,the more the line is definitely controlled by the guide. Vibration,irregularities of surface, wound substance condition, and machinegearing have considerably less effect on the short line. Also, theshorter the relative distance, the greater the mechanical advantage. Inthe early stages a great amount of guide action results in littlesubstance wound. As the winding progresses, more and more substance iswound for the same amount of guide action.

If the ratio of turn of spindle to stroke of guide is adjustable and thesubstance to be wound will payout satisfactorily from such a wind, amultiplex wind should be considered. Such a wind has more than two turnsof the spindle to one complete stroke of the guide, the overage beingadded usually in multiples of 180.

Since this method allows unlimited choice of angles of wind, the angleof wind should be given careful consideration. It depends on the machineto be used, the substance to be wound, and the result to be achieved.-Some substances that are subjected to damaging shearing action at across-over angle of are amply protected at angles either considerablysmaller or larger than this, say at approximately 30 or Also somesubstances will payout at high speeds from small angle winds whileothers will do better at wide angles, depending on the type ofsubstance, its relative spring characteristics, and its cross-sectionalshape and on the mass, shape, and size desired in the finished package.

This same method can be used to produce mandrels with variations incenter section shapes similar to those shown in my patent applicationS.N. 344,875, filed March 26, 1953, now Patent No. 2,828,092, and toproduce mandrels in which the center section is conical in one directiononly rather than in two.

It should be apparent that this method of producing and adjustingmachinery, which makes possible the laying on of slippery substancesunder minimum tension and which results in maximum utilization of selfsupport characteristics, provides unlimited opportunities for improvingboth the mechanics of winding and the packages that result. It shouldopen up to all bendable substances types of winding machines and formsof winding that have heretofore been reserved for specific substanceswhose peculiar characteristics have allowed satisfactory results withrelatively undeveloped winding processes. Although the elements involvedand the advantages to be gained are too numerous to list in detail, oneversed in this art should be able to balance one factor against anotherso as to succeed in designing satisfactory, self supporting packages formany substances formerly thought to need strong support and for manysubstances heretofore found impracticable to wind.

After consideration of the characteristics of the substance to be wound,the mass or amount of it to be built into a package, the type of payout,and the shape of the finished package preferred, some of the mostimportant factors to be considered in designing the winding are theminimum diameter, the ratio or order, the angle at which to Wind, theadvance of the wind, the particular shape and the final diameter. Withthese determined, anyone versed in this art can use this system ofdesign both to design the mandrel and end forms on which to wind and toset or adjust the machinery so as to achieve the winding.

FIGURES 15 to 18 show the collapsing of various winds according to theinvention.

In selecting winds to be produced by this new method, the designer isnot limited to the plus, minus, and combination plus/minus advance windsof my Patents No. 2,634,916 and No. 2,634,922, issued April 14, 1953 andapplications S.N. 344,874, new Patent No. 2,767,938 and S.N. 344,875,now Patent No. 2,828,092 filed March 26, 1953, which payout through aradial hole.

Industry has been finding many uses for end payouts from cops, spools,and reels and from specialized packages. In general, these have beenlimited to over end (outside) payouts, with consequent difliculties.Although relief from the cost of cops, spools, and reels, and from someof the intricacies of specialized packages provides one incentive forreplacing the present types of packages with self-supporting windings,the center payout made possible by self-supporting winds, with itscontrol of both payout and centrifugal loop and its firstin-first-outprinciple, offers additional incentive in many cases.

For either center or over end payout, the plus, minus, and combinationplus/minus advance winds, wound by the new method but without the radialhole, can be used. Of course, windings with the radial hole can be payedoif from the end, if the user shoulder prefer it, by ignoring the radialhole. However, there are advantages in winding without the hole if it isknown to be not needed.

In winding many substances with the new method the advance can be closedup considerably, so as to reduce the air spaces within the layers,without causing damage to the substance. With substances of this typeand especially with others that will not allow closing the advance, thefinished mass can be reduced by collapsing the wound package underpressure. Greater protection in packaging, improved control of payout,higher speed of payout, and greater linear speed with less rpm. inwinding are other advantages that can be gained through this collapse.

Various forms of collapsed winds are possible, each type havingdifferent characteristics that are advantageous. First, there is partialor complete collapse circumferentially. This includes winds both withand without the radial hole.

Second, there is partial or complete collapse axially. This alsoincludes winds both without and with the radial hole, it being specifiedthat the radial hole be kept open by the insertion of either a temporaryor permanent plug or tube while the other portions are collapsed.

Although I do not claim to have invented all forms of collapsed winds assuch, packages wound with my method make possible many improvements inthis specialized art and collapsed winds which originate from thismethod have definite advantages.

FIGURE 15A shows a package 70a produced according to the invention witha radial hole '72. This is a one wind. The hole may be omitted ifdesired.

FIGURE 15B shows the same package 7012 collapsed radially by centralpressure. Upon such collapse, the central portion 74b is more reduced indiameter than the ends 76b.

FIGURE 15C shows one end 780 of the package 70c collapsed to the samediameter as the central portion 74c. Both ends may be so collapsed ifdesired.

FIGURE 16A shows a two wind package 80a. FIG- URE 163 shows the samepackage 80b radially compressed and elongated. FIGURE 16C shows the samepackage 80c reduced in diameter at several points. FIG- URE 16D showsthe same wind 80d further elongated with one end 82d maintained at thesame diameter as in FIGURE 16A.

In FIGURE 17A, package 84a is a one wind with a narrow winding angle.FIGURE 17B shows the same package 84b compressed axially.

FIGURE 18 shows a conically shaped package 85 collapsed axially.

The package 86a of FIGURE 19A is a two wind with a small winding angle.The same package is shown axially collapsed at 86b in FIGURE 19B.

The package 88 of FIGURE 20A is wound in the manner described above witha radial opening 90. This package is then collapsed circurnferentiallyby enlarging the radial opening by pressure on its ends in the directionof the arrows 92. This will then assume the form 88b of FIGURES 20B and20C, the bights of the figure 8s then forming piles lying side by sideand of frustoconical shape.

For dispensing such a package, I may provide a board or flat plate 94(FIGURES 21A to 21C) provided with notches 95 through which extend thelegs E8 of a U- shaped spring member, whose legs carrying slightlyhooked blocks for engaging the narrow waist of the package 8817. Theends of the package may be engaged by arms 10?. pivoted at 104 onuprights 1% carried by board 94, and pressed in any suitable manner, asby their own weight, against the package ends.

FIGURE 22 shows package 8817 enclosed in a box 108, with its free innerend guided out of the box by tube 110.

The package 112 of FIGURES 23A and 233 can be formed from amultiple-order wind, such as that of FIG- URE 16A but provided withradial openings, by opening them up in the same manner as in FIGURES 20Ato 20C.

In FIGURE 24 a package such as 86b is enclosed in a box 114 having acover 116 in which is fixed a tube 118 through which the inner end 120of the material is led out. The box has a bottom cone I22 and a top cone124, the latter having a central hole therein. These cones are formed atthe angle of the interior flaring end surfaces of the package, and restagainst them to hold the package against distortion and to ensure properpayout.

In addition to collapse, another factor which offers a way to controlpayout of some substance is partial, or total, release of tension in thecoils of the package. This is brought about by slacking slightly, whileunder control, the outer end line of the package. With some substance, agentle shaking of the package helps to transfer and equalize theslackening throughout all the coils of the package.

Although this slacking off is an aid to collapsing and usually resultsin collapse to some degree, packages can be collapsed under pressurewithout such release. This release of tension in the coils removes someof the tenden' cy of the coils to resist, by their own spring, thetorsion, or twisting and turning, to which they are subjecting whilepaying out. It thus results in a smoother running line which has littledanger of interfering with later neighboring coils. It is effective inpaying out through a radial hole as well as from the inside and outside,over the end, of self-supporting packages.

The invention further contemplates improvements in the spools and themachines used for winding many substances, especially fiat substancessuch as tape. For any except truly random winds, a spool (01' reel) withincorrectly angled flanges, or a machine setting incorrectly planned fordistance of guide from axis or for width of guide stroke, will cause amisalignment of the wound substance which is apt to result in damage tothe substance either in the wound package or during subsequentunwinding.

In many cases, the results of such misalignments are important enough tocause the use of involved and expensive machinery which eithereliminates the misalignment or removes some of its most apparentmisformations, as shown, for example, in Patent No. 2,513,815, issued toO. G. Nelson, July 4, 1950. In other cases, misaligned windings are usedbecause no simple means of improvement have been known.

In practically all cases, improved winding is now possible through theuse of this method. Since the Winding of flat strip, or tape, has alwaysproved difficult, a spool for Winding /2 wide strip, with the furtherspecification that a large mass is to be achieved, is shown.

One of the first things to be considered in winding strip is the minimumradius of the sphere or end arc on which to wind it. FIGURE gives someidea of the problem by showing the curvature of arcs at several radiuslengths compared to a /2" flat Width. In this drawing, it appears that a3" radius would be satisfactory. This leaves the substance lying onabout 8 of the circle. At a smaller radii, there would be such acontrast between the curve and the flat that the edges of the /2" wideflat substance could be expected to ripple or the center part of thestrip might become stretched. This has to do with the arcuate parts ofthe spool only, as the strip will lie fiat, in helical form, on thecylindrical central portion. This minimum sphere radius is the radius ofthe cylinder for the minimum stage.

In this figure, various arcs (126 12-6 126 126 are drawn at 1" intervalsabout center 126. Lines 13%, 13W, spaced /2" apart represent the widthof the tape sections 132 132 132 132 It will be apparent that at 3" orover the tape will deviate but little from the arc.

The next consideration is the maximum radius. This decision is relatedto the final mass to be achieved and to many factors based on either theuses of the spooled substance or the machine to be used and itslimitations. However, in this case, it was arbitrarily selected at 12",with a deduction of /2" for safety in operation. This maximum radiusdetermines the radius of the base stage.

Having determined the minimum and maximum radii, the next considerationis the angle at which to wind. The problem is to lay the consecutiveturns approximately next to each other in all layers. They are not to beallowed to overlap on the one hand but, on the other, it kept too farapart, the wind will contain more air spaces than necessary. Thisconcerns the turns on the cylindrical portion rather than the endformation and can be worked out through the use of cylindricalgenerating line angles, the generating line angle being such that atleast /2" of progress along the cylinder is gained for each 360 of turn.

FIGURE 26 shows the shape of a spool of 3 diameter using a winding angle(1 of 3 30', although an angle as small as 1 30 could be used. Asidefrom the wind ing angle, the count, or ratio of turns of spindle to halfstrokes of the guide, and the advance are the two factors remaining. Thecount is directly related to the mass. It can be extended indefinitelyuntil sufficient cubic space to contain the required amount of substanceis within the minimum and maximum diameters. A count of 30 seemssatisfactory. The advance is not of great importance in this kind ofwind as each half stroke of the guide from one side of the winding tothe other lays almost a completely covered layer of substance. Anadvance of 12 was selected for illustration. As formerly, this is theamount of advance measured along the center line of the spool.

Because the drawing plots the helix of the center line of the A2 widestrip, and adjustment of A; in width must be made for the placing of theend cones. This adjustment is made by measuring A" additional on thespherical end of the center portion of the spool and joining the endcone lines and the limit line for the basic layer, through the newpoint.

In forming such a spool, we will take for example a machine which is towind a tape of half-inch width (w) on a spool, the guide being locatedat a distance of 12 inches (2R) from the axis of rotation A-A, and thetape to make 30 turns around the spool (Ct=30) in each layer, with anadvance (a) of l2. The winding angle (00 is 3 30. The half-length (G) ofthe guide stroke should be RhtCi- HW equal to lt hnti l which is 3 30.5.This line crosses the axis at point ill. From point 111, I draw endgenerating line 112 at an angle to the center line of Zuni-fill! or 1 31where tart I also draw a perpendicular 113 from point 111 to line R at114.

From point 114, I draw line 115 sloping towards center line C at anangle or 0 45.5 intersecting axis A at 116. From 116, I drawperpendicular 117 117 to lines R R With 116 as a center and radius R, Ithen draw arcs 118 118 Through points 119 where are 118 intersects line112 and through the corresponding point on are 118 designated by line119 -119 vertical to the axis, I draw (broken) lines 120 120 at angles[int (or 5 30') to the center line C. Since the winding line representsthe center of a one-half inch strip, a one-fourth inch space must beadded, and lines 121 121 representing the end form lines are drawnparallel to lines 120 120 but spaced outwardly one-fourth inchtherefrom,

Now, assuming a 3" radius (R,}) for the finished spool, I draw frompoint 221 :a line 122 at an angle tanintersecting axis A at 127. With127 as a center and 18 'y' is 2a'-}9', 6 is sin" (cos '9' tan 772), andR is the radius at which the winding angle is a.

2. A package of flexible material wound in a series of figure 8s inwhich the crossovers of successive figure 8s are angularly displacedaround the package, said package having an internal surface defining anaxial opening therethrough, said surface having a cylindrical centralportion, a portion of decreasing diameter at each end of said centralportion, and end portions flaring outwardly at an angle 5' to the axisof the package, the winding angle oc at any diameter r of the packagebeing represented by the formula:

radius R arcs 128 128 are drawn to intersect flange lines 121 121 LinesR R arcs 128 12 8 and lines 121 121 then define one-half of the spool.

In FIGURES 27 and 28, a spindle is shown formed of several parts capableof being withdrawn from inside the package. The shaft of the windingmachine is shown at 140. Around this shaft fit five parts 141, 142, 143,144, 145 which together are shaped to make up the cylindrical portionand the portions of outwardly decreasing diameter of the spindle. Theseparts project at each end into recesses provided in conical end forms146, which can be fixed on the shaft by collars and set screws 147.

With this arrangement, after a package is wound, the set screws can bereleased and the collars and spindle parts are pulled off the shaft, andthe various parts 134 to '145 are pulled out through the ends of thepackage, part 141 being removed first. They can then be reassembled onthe shaft and another package can be wound.

This same method can, as shown in FIGURES 29 and 30, be used to producemandrels with variations in center section shapes similar to those shownin my patent application SN 344,875, filed March 26, 1953, now PatentNo. 2,828,092 and to produce mandrels in which the center section isconical in one direction only rather than in two.

While I have described herein some embodiments of my invention, I wishit to be understood that I do not intend to limit myself thereby exceptwithin the scope of the claims hereto or hereinafter appended.

I claim:

1. A package of flexible material wound in a series of figure 8s inwhich the crossovers of successive figure 8s are angularly displacedaround the package and a succession of such figure Ss progressing oncearound the package forms a layer, said package having an internalsurface defining an axial opening therethrough, said surface having acylindrical central portion, a portion of decreasing diameter at eachend of said central portion, and end portions flaring outwardly at anangle 6' to the axis of the package, the width of the layer at radius Rbeing where a is the advance which may be positive or negative, N is theorder of the wind, (1' is 2 tan B tan 7T where a is the advance whichmay be positive or negative, N is the order of the wind, on is sin w-aq]where a is the advance which may be positive or negative, N is the orderof the wind, 0. is

2 tan 6' is 2a'fl', 6 is sin- (cos 'y tan 'y'/2), and R is the radius atwhich the winding angle is a.

4. A spindle for winding machines having a cylindrical portion of radiusR and of length at each end of the cylindrical portion a sphericalportion of outwardly decreasing diameter of radius R and projecting onthe spindle axis a distance outwardly flaring end forms at an angle 18'to the center line normal to the axis, where a is I tan 1 2 tan 6 a isthe chosen advance which may be positive or negative, and N is theorder, which is an integral multiple of onehalf.

5. A spindle as claimed in claim 4 having the cylindrical and sphericalportions formed of a plurality of parts divided by planes substantiallyparallel to the spindle axis,

